Seitan bacon product

ABSTRACT

A product includes simulated bacon slices containing, as ingredients, (i) a mixture of Adzuki beans, liquid smoke and water, (ii) a mixture of buckwheat groats, water and liquid smoke, and (iii) wheat gluten flour; and a topping sauce containing mixed bacon seasoning, coconut oil and liquid smoke. The simulated bacon slices with the topping sauce are packaged and labeled as a simulated bacon product.

CROSS-REFERENCE TO RELATED DOCUMENTS

This application is a continuation of U.S. patent application Ser. No.15/285,246 filed Oct. 4, 2016, which is a divisional of U.S. patentapplication Ser. No. 14/558,045 filed Dec. 2, 2014, which claimspriority to U.S. Provisional Patent Appl. No. 62/066,090 filed Oct. 20,2014. The entire contents of the above-referenced applications arehereby expressly incorporated herein by reference.

BACKGROUND OF THE INVENTION Field of the Invention

The present invention is in the technical field of food products andfood processing and pertains particularly to methods and apparatus forcreating a simulated bacon product, and the product itself.

Discussion of the State of the Art

It is well-known that pork bacon is a staple of foodstuff and a stapleof breakfast menus in America and other cultures as well. It is alsowell-known that pork bacon is fatty and rather high in calorie count.Further there is a well-established movement in commercial enterprisesto create meat products that actually contain little or no meat at all,but rather are made primarily from vegetable and grain ingredients. Theskilled person will be aware, for example, of veggie burgers, and ofother pseudo-meat products.

But it is also true that many such products that simulate meat but areactually predominantly vegetable or grain, or both, most usually fail toaccomplish the real taste and texture of the meat products they aremeant to imitate or replace. There is, therefore, still an unmet needfor a product made from vegetable and/or grain matter that approachesthe real texture and taste of pork bacon. The present inventors havedeveloped just such a product, through long scientific study andexperiment, and thorough creation of many versions, each better than thelast, arriving finally at products made from ingredients and in aprocess taught in considerable detail below in different embodiments.The inventors are quite sure that the processes taught in that documentwith the ingredients listed in the proportions listed, and the resultingproduct are unique and not obvious over any such product and processexisting in the public domain at the time of filing the present patentapplication.

SUMMARY

In one embodiment of the invention a process for making a simulatedbacon product is provided, comprising: (1) mixing dry ingredients forbacon seasoning in a container, and storing the mixed ingredients; (2)mixing adzucki beans, liquid smoke and water, and storing the mixture;(3) mixing buckwheat groats, water and liquid smoke, and storing themixture; (4) processing the mixture from step (2) to a smooth texture,and storing the processed mixture; (5) processing the mixture from step(3) to a smooth texture, and storing the processed mixture; (6)combining the processed mixtures from steps (4) and (5), addingadditional wet ingredients, blending, and storing for later use; (7)preparing a topping sauce by adding liquid smoke and olive oil to dryingredients including bacon seasoning; (8) adding mixture from step (6)to dry ingredients including at least wheat gluten flour, mix to dough;(9) separating dough into loaves of a predetermined size, and placingthe loaves into individual cooking baskets, and baskets into cookingskillets, then cooking for a predetermined time and temperature; (10)placing loaves into slicer, and slicing into bacon strips; (11) addingtopping sauce from step (7) to bacon slices; and (12) packaging andlabeling slices for distribution and sale.

In one embodiment in step (1) the ingredients comprise garlic granules,onion powder, tomato powder, smoked paprika, chili powder, cumin, blackpepper, powdered mustard, sage, rosemary, evaporated cane juice, andsalt. Also in one embodiment, in step (6), the additional wetingredients comprise nutritional yeast, soy sauce, tomato paste, maplesyrup, apple cider vinegar, liquid hickory smoke and coconut oil. Alsoin one embodiment, in step (9), the loaves are shaped such that, whensliced, the slices will approximate length and width of bacon slices.And in one embodiment the order of predominance for ingredients isevaporated cane juice and smoked paprika in equal amounts, followed bytomato powder, garlic granules, and onion powder.

In another aspect of the invention a simulated bacon product isprovided, comprising strips of simulated bacon cut from a loaf preparedby mixing dry ingredients for bacon seasoning in a container, andstoring the mixed ingredients, mixing adzucki beans, liquid smoke andwater, and storing the mixture, mixing buckwheat groats, water andliquid smoke, and storing the mixture, processing the adzucki beanmixture to a smooth texture, and storing the processed mixture,processing the buckwheat groats mixture to a smooth texture, and storingthe processed mixture, combining the processed adzucki bean and groatsmixtures and adding additional wet ingredients, blending, and storingfor later use, preparing a topping sauce by adding liquid smoke andolive oil to dry ingredients including bacon seasoning, adding themixture of the processed beans and groats mixtures to dry ingredientsincluding at least wheat gluten flour, and mixing to a to dough texture,separating the dough into loaves of a predetermined size, and placingthe loaves into individual cooking baskets, and baskets into cookingskillets, then cooking for a predetermined time and temperature, placingthe loaves into a slicer, and slicing into bacon strips, adding thetopping sauce to the bacon slices, and packaging and labeling the slicesfor distribution and sale.

In one embodiment of the simulated bacon product the ingredients for thebacon seasoning comprise garlic granules, onion powder, tomato powder,smoked paprika, chili powder, cumin, black pepper, powdered mustard,sage, rosemary, evaporated cane juice, and salt. Also in one embodimentthe additional wet ingredients comprise nutritional yeast, soy sauce,tomato paste, maple syrup, apple cider vinegar, liquid hickory smoke andcoconut oil. Also in one embodiment the loaves are shaped such that,when sliced, the slices will approximate length and width of baconslices. And in one embodiment the order of predominance for ingredientsis evaporated cane juice and smoked paprika in equal amounts, followedby tomato powder, garlic granules, and onion powder.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a process flow chart depicting steps for preparing baconseasoning used in a sliceable bacon product.

FIG. 2 is a process flow chart depicting steps for pre-soaking adzukibeans used in a bacon base in the sliceable bacon product.

FIG. 3 is a process flow chart depicting steps for pre-soaking groatsused in the bacon base in the sliceable bacon product.

FIG. 4 is a process flow chart depicting steps for processing the adzukibeans into a smooth texture.

FIG. 5 is a process flow chart depicting steps for processing the groatsinto a smooth texture.

FIG. 6 is a process flow chart depicting steps for preparing the baconbase.

FIG. 7 is a process flow chart depicting steps for preparing bacontopping sauce.

FIG. 8 is a process flow chart depicting steps for preparing baconloaves.

FIG. 9 is a process flow chart depicting steps for slicing bacon stripsfrom bacon loaves.

FIG. 10 is a process flow chart depicting steps for packaging andsterilizing bacon strips.

FIG. 11 is a process flow chart depicting steps for quality controlscanning bacon strip packages and final packaging of multiple singlepackages for latter shipment.

DETAILED DESCRIPTION

The inventors teach a manufacturing process and ingredients forpreparing a simulated bacon product for public consumption. The presentinvention is described in enabling detail using the following examples,which may describe more than one relevant embodiment falling within thescope of the present invention. The simulated bacon product is formedinto a loaf and cooked before slicing and packaging the product tosimulate real sliced and cured bacon.

One aspect of preparing the simulated bacon product includes preparationof a bacon seasoning. FIG. 1 is a process flow chart 100 depicting stepsfor preparing bacon seasoning used in a sliceable bacon productaccording to an embodiment of the present invention. The bacon seasoningincludes an assortment of dry ingredients that may be gathered togetherat step 101. The ingredients may include, but are not limited to garlicgranules, onion powder, tomato powder, smoked paprika, chili powder,cumin, black pepper, powdered mustard, sage, rosemary, evaporated canejuice, and salt.

The dry ingredients for the bacon seasoning are combined in a containertermed by the inventors a food lug at step 102. The food lug in oneembodiment has a length, width, and a depth, and has a lid to secure thecombined contents. In one embodiment the ingredients are mixed by handusing a whisk or other mixing implement for dry ingredients. IN otherembodiments the mixing may be by a powered mechanical device. The exactdimensions of the lug may vary depending upon the batch size of thebacon product for which the seasoning is being prepared.

The lug in one embodiment is labeled in step 103 with pertinent dataidentifying the contents, the date and time the contents were placed inthe lug, and a lot code associating the lug with other lugs carryingother ingredients. At step 104 the ingredients are set aside or storedin a dry storage for later use in preparing the simulated bacon product.The exact amount of each dry ingredient used in the bacon seasoning mayvary considerably. The dominant ingredients with respect to ratio of thewhole include evaporated cane juice, smoked paprika (equal amounts)followed by tomato powder, garlic granules, and onion powder.

One aspect of preparing a simulated bacon product includes preparationof a bacon base having adzuki beans as a prominent ingredient. FIG. 2 isa process flow chart 200 depicting steps for pre-soaking adzuki beansused in the bacon base in the sliceable bacon product in one embodiment.The adzuki beans are gathered and washed and liquid smoke and water arerendered available in step 201. The adzuki beans are combined with theliquid smoke and water mixture in a second food lug with lid at step202. At step 203 the lug is labeled with pertinent data including lotcode, product identification (marinating adzuki beans), and date andtime product was placed into the lug. At step 204 the lug is placed in acold storage, such as a refrigerator unit, to marinate for a period oftime. The time allotted for this process is approximately 24 hours butmay be more or less than 24 hours without departing from the spirit andscope of the present invention.

One aspect of preparing the simulated bacon product includes preparationof groats used in the bacon bean base. FIG. 3 is a process flow chart300 depicting steps for pre-soaking groats used in the bacon base in thesliceable bacon product. At step 301 buckwheat groats are obtained alongwith liquid smoke and a source of water. At step 302, the groats arecombined with the liquid smoke and water in a third food lug. At step303 the groats are soaked in the water and liquid smoke mixture for apre-defined period of time. An exemplary soaking time for the groats maybe approximately four hours, but this time may vary in differentembodiments.

After soaking the liquid is strained off of the groats at step 304. Thegroats are placed in a fourth food lug with lid at step 305. At step 306the lug is labeled with pertinent data including lot code, productidentification (soaked groats), and date and time product was placedinto the lug. At step 307 the groats are stored or set aside in coldstorage for later use. Groats must be retrieved from storage and usedwithin five days of refrigerated storage. The adzuki beans describedfurther above and the groats are in one embodiment the primaryingredients of the adzuki bean bacon base. Together they make up morethan sixty percent of the bacon base mixture.

FIG. 4 is a process flow chart 400 depicting steps for processing theadzuki bean mixture stored with reference to FIG. 2 above into a smoothtexture. At step 401, the adzuki beans may be retrieved fromrefrigerated storage. At step 402 the liquid is drained off of theadzuki beans. At step 403, the beans may be placed in a food processingunit such as a Hobart food processor. At step 404 the beans may beprocessed in the food processor until a smooth texture similar to apaste is achieved with minimal lumping. The processed beans may beplaced in a fifth lug with a lid at step 405. At step 406 the lug islabeled with pertinent data including lot code, product identification(processed adzuki beans), and date and time product was placed into thelug. At step 407, the processed adzuki beans are placed back in coldstorage such as a refrigerator unit for storage until later use.

FIG. 5 is a process flow chart 500 depicting steps for processing thegroats into a smooth texture. At step 501, the refrigerated groats areretrieved. At step 502 the groats are placed in a food processor such asthe Hobart food processer mentioned further above. At step 503, thegroats are processed for a smooth texture similar to a paste like Humusfor example. At step 504 the groats may be placed in a sixth lug withlid. At step 505 the sixth lug is labeled with pertinent data includinglot code, product identification (processed groats), and date and timeproduct was placed into the lug. At step 506 the groats are placed backinto refrigerated storage, or are set aside for later use.

FIG. 6 is a process flow chart 600 depicting steps for preparing thebacon base. At step 601 processed adzuki beans and groats are retrievedfrom cold storage in preparation for mixing the bacon base used in thesliceable bacon product. In addition to the primary base ingredients(adzuki beans, groats), the bacon base may include onion powder,nutritional yeast, smoked paprika, soy sauce, salt, tomato paste,coconut oil, maple syrup, apple cider vinegar, and hickory smoke. Theprocessed beans and groats are placed in a large mixing bowl at step602. The capacity of the bowl may vary according to batch size withoutdeparting from the spirit and scope of the present invention. In thisexample an 80 quart bowl is used in conjunction with a Hobart mixer. Atstep 603 the processed foods are mixed together with the mixer untilwell blended.

Other bean/bacon base ingredients may be added to the blend at step 604.In one implementation the added ingredients may include nutritionalyeast, soy sauce, tomato paste, maple syrup, apple cider vinegar, andliquid hickory smoke. In this implementation the ingredients alsoinclude coconut oil. The coconut oil may have to be warmed to a liquidbefore adding to the mixture. In one implementation smoked paprika,salt, and onion powder might be added in small amounts for seasoning. Inanother implementation, no seasoning is added to the blended mixture. Atstep 605, the ingredients are all blended together with the groats andbeans using the Hobart mixer unit or similar implement to make theblended bacon base. At step 606 the blended mixture may be poured into acontainer with lid. The capacity of the container for storing theblended bacon base may vary according to batch size. In this example,the container is a 20 quart container. At step 607 the container islabeled with pertinent data including lot code, product identification(blended bacon base), and date and time the product was placed into thecontainer. At step 608 the blended bacon base is set aside in coldstorage for latter use in preparation of the simulated bacon product.

One aspect of preparing the simulated bacon product includes preparationof a bacon topping sauce used on the simulated bacon product. FIG. 7 isa process flow chart 700 depicting steps for preparing the bacon toppingsauce. Ingredients for the bacon topping sauce in one embodiment includebacon powder, bacon seasoning, salt, olive oil, and liquid hickorysmoke. Dry ingredients used in the process are gathered at step 701. Thedry ingredients are combined in a seventh food lug with lid at step 702.Liquid smoke and olive oil may be added to the dry ingredients at step703. The ingredients may be combined at step 704 using a whisk andemersion blender.

In one implementation for a larger batch, the ingredients may be blendedfirst with a whisk in the food lug. The mixture may then be transferredto a Hobart 80-quart mixing bowl where the sauce is mixed using a Hobartmixer for the following speed/times: speed 1 for 1 minute, speed 2 for 2minutes and speed 3 for 3 minutes. Capacities of mixing bowls and mixingspeeds and times may vary according to batch size and ambientconditions. In one implementation the bacon topping sauce may bere-combined before use with an emersion blender. If mixed sauce has beenrefrigerated, it must be remixed using either the Hobart mixer oremersion blender prior to use. The sauce may be set out fromrefrigerated storage for approximately 20 minutes prior to mixing withemersion blender.

The bacon topping sauce may be poured into a sauce container at step705. The container may be labeled in step 706 with pertinent data suchas lot code, product identification (bacon topping sauce), and date andtime the product was placed into the container. The container of saucemay be placed in cold storage such as a refrigeration unit for lateruse.

One aspect of preparing the simulated bacon product includes preparationof a bacon loaf that may be sliced into bacon strips. FIG. 8 is aprocess flow chart 800 depicting steps for preparing bacon loaves.Ingredients for the bacon loaf include vital wheat gluten (seitan),water, the adzuki bean/bacon base (FIG. 6 ), the bacon seasoning (FIG. 1), annatto, olive oil, and bacon powder. In one implementation the baconloafs are cooked in tilt skillets for industrial use.

The tilt skillets may be prepared for cooking a batch of simulated baconloaves at step 801. Preparation in this regard includes combining water,liquid hickory smoke, and caramelized sugar in as many skillets asneeded to process a batch of bacon loaves. At step 802 the dryingredients for the simulated bacon loaf are gathered. The dryingredients (vital wheat gluten flour, Bacon seasoning, bacon flavorpowder, and annatto) are placed in a large mixing bowl such as a Hobartmixing bowl described previously and are combined together by mixing.

The adzuki bean base, olive oil and water may be added to the mixingbowl containing the dry ingredients at step 804. At step 805 theingredients are mixed thoroughly. In this example the mixing speed maybe low speed for one to two minutes and medium speed for approximatelytwo minutes. At step 806 the contents are placed into a bus tub. Thecontents are kneaded into a dough at step 807 in the bus tub the mixtureassuming the shape of the bus tub. The top of the loaves are flattenedif necessary to promote uniform thickness dimensioning of each loaf.This is a step influencing the size of bacon strips to be later slicedfrom the loaf.

The dough may be separated into individual loaves at step 808. In thisexample a pre-cooked loaf measures approximately six inches wide by 8inches long by 1.5 inches thickness. Each loaf may weighs approximately2.2 pounds. This is not a limitation of the invention but a variablethat influences size of slices for bacon product. The individual loavesmay be placed into individual cooking baskets designed to be used withthe tilt skillets in step 809. At step 810 the baskets are placed intothe tilt skillets.

In step 811 the loaves are cooked for a period of time. The cookingbaskets may hold two loaves each in one implementation. A large batchmay require as many as 25 to 30 cooking baskets for 50 or more loaves.The loaves are boiled for approximately 60 to 70 minutes. At step 812the cooking may be monitored to determine if the loaves are sufficientlycooked or “done”. If it is determined that they are not through cooking,the process might resolve back to step 811 until next check. If it isdetermined at step 812 that the loaves are finished cooking the processmoves to step 813.

At step 813 the loaves are removed from skillets and baskets and placedon screens and put on refrigeration racks. There might be 6 to 8 loavesper screen. The loaves are cooled in step 814 for a time period ofapproximately 20 minutes before cold storage. The loaded refrigerationracks may be covered with plastic and labeled with pertinent data instep 815. The data may include lot code, product name and date. Theplastic cover may be perforated to provide ventilation. The product isplaced into or wheeled (on rolling racks) into a freezer unit at step816 until slicing time. It is noted herein that the simulated baconloaves may be sliced optimally when they have cooled to approximately 32degrees.

FIG. 9 is a process flow chart 900 depicting steps for slicing baconstrips from bacon loaves. At step 901 bacon loaves previously placed onracks in cold storage are retrieved and allowed to warm up toapproximately 32 degrees before slicing, if they are colder than theoptimum temperature. 32 degrees F. represent a “goldilocks” temperaturefor slicing. If bacon loaves reach 38 degrees F. they are to warm tomaintain accurate thickness at slicing. In one implementation the loavesare sliced using a computer numerical control (CNC)-enabled industrialslicer machine like a Grote slicing machine for example, having loadingcartridges and a material entry chute.

The slicing machine is set up for bacon slicing at step 902. In thisimplementation using an industrial slicing machine, the bacon loaves arewheeled over to the slicer on half speed racks from cold storage. Up tofour loaves are auto-loaded into one bacon cartridge numericallycontrolled, automated slicing. In one implementation a new slicing bladeis installed before starting slicing of a new batch. The machine mayalso be sanitized as required before starting slicing operations. Baconloaves, cooled to approximately 32 degrees Fahrenheit, are loaded intothe slicing machine at step 903. If loaves are too wide to fit in theloading chute, the sides of the loaves may be trimmed to fit. Each baconcartridge will hold up to four bacon loaves for slicing. At minimum,each cartridge should be loaded with three bacon loaves for slicing foreven weight distribution and slicing consistency relative todimensioning.

The desired thickness of a sliced strip of bacon may be pre-programmedusing a computer interface associated with the slicing machine at step904. Slicing may be initiated at step 905. Loading of more loaves intothe slicer may be performed on prompt by the machine as bacon is slicedand removed from cartridges. Slicing thickness of sliced strips ofsimulated bacon may be checked periodically in step 906 using normalquality control (QC) checks while the product is processed. In oneimplementation, QC on slice thickness is performed every few minutesduring active automated slicing. A user/operator may determine whetheror not to make a slicing thickness adjustment on the machine in step 907based on the last QC check of slice thickness. In one implementationthis process may be somewhat or fully automated depending upon machinecapabilities and features.

If the user or operator determines not to adjust the thickness, theprocess may resolve back to step 906 until the user makes adetermination to adjust the thickness setting or until the product isfinished. If the user determines to adjust the slicing thickness at themachine interface in step 907 the adjustment may be implemented at step908. If the product is not finished, the process resumes automatedslicing at step 905. An industrial slicer may use water as a slicingblade lubricant during slicing operations. Therefore water levels mayalso be periodically checked to ensure proper lubrication and minimalblade friction against the product. It is noted herein that steps forquality control and machine maintenance may be reduced or eliminated ifthe batch is small. For larger batches more QC and machine maintenancemay be appropriate.

At step 909 the operator determines whether the product has been sliced(done slicing). If the process is not complete the process resolves backto step 905 for resumed slicing. If the user is finished slicing in step909, the operator removes the rest of the bacon product from thecartridges at step 910. The individual simulated bacon slices may bestacked in a large container or one or more sanitized tubs in step 911.The tub of simulated bacon slices may be labeled with lot code, productidentification (simulated bacon loaf slices), and date produced, andplaced in cold storage (refrigeration/freezer unit) at step 912 untilpackaging is required.

In one implementation, any bacon scraps are removed from the slicingmachine at step 913 approximated every 30 minutes for large batchprocessing. The scraps might be labeled and stored in a freezer unit forlatter disposition in step 914. The slicing machine may be cleanedthoroughly in step 914 in preparation for another run of the same ordifferent product which may occur as the process resolves back to step903 if another product run is required for the same product. Otherwisethe process ends for that batch after step 915.

FIG. 10 is a process flow chart 1000 depicting steps for packaging andsterilizing bacon strips. At step 1001 sliced simulated bacon may beremoved from cold storage to undergo packaging. A predetermined numberof simulated bacon slices are arranged in shingle fashion (edgesoverlapping) on a weighing scale in step 1002. In a preferred embodimentminimum weight for bacon slices should be about 17 grams while maximumweight should be about 19 grams.

In step 1003 it is determined whether the arranged stack of bacon slicesmakes the nominal weight (within weight tolerance). If it is determinedthat the product weighs correctly at step 1003, a measured amount ofbacon sauce in poured over the top of the shingled stack of slices instep 1005. If it is determined at step 1003 that the product is toolight or heavy, the operator may add or remove a slice to make therequired weight at step 1004. The process then moves to step 1005 forthe bacon sauce application. The measure of bacon sauce is approximatelyone half ounce.

It is noted herein that ideal weight is approximately 18 grams for asingle bacon slice. The exact number of bacon slices arranged in shinglefashion on the scale depends upon collective weight of shingled stack.For example, a minimum weight for 8 slices may be 136 grams while amaximum weight for the same may be about 152 grams. 144 grams is theideal or nominal weight for a stack of simulated bacon slices. A slicemay be added or subtracted from a shingled stack to adjust the overallweight while the product is scaled. At this point a small amount of thetopping sauce may be added.

The stack of bacon is placed, if not already, on a vacuum package(pouch) for vacuum packaging in step 1006. At step 1007 the packaged isvacuum sealed. Steps 1001 through 1007 may be performed in a loopedfashion until all of the bacon slices are in vacuum packages. A step1008 is determined if the process up to vacuum packaging is complete. Ifit is not complete at step 1008 the process resolves back to step 1002.If vacuum packaging is complete, the packages are once again placed intilt skillets filled with water (used also for cooking) forpasteurization at step 1009.

The water in the tilt skillet(s) is brought to a rolling boil of 212degrees with the packages submersed in the skillets at step 1010. Thepackages are left in a boiling state at step 1011 for a pasteurizationperiod of approximately 4 minutes (time may vary according to differentlot sizes). In step 1012, a package may be removed from a tilt skilletand tested for temperature. This might be performed by puncturing thepackage with a thermometer capable instrument.

It is determined at step 1013 whether the product inside the package hasreached an acceptable temperature for pasteurization. An acceptabletemperature in this example is approximately 180 degrees F. If theproduct tested at or above the right temperature in step 1013, thepackages of simulated bacon slices may be removed from the associatedtilt skillet at step 1014. If the tested package does not make thetemperature requirement in step 1013, the process may resolve back tostep 1011 for added wait time.

Packages that have passed the pasteurization process are placed in coldwater sinks to cool down at step 1015. At step 1016 the pasteurizationand cooking information (times product amounts) may be documented forfuture quality control data. The cooled packages of simulated bacon maybe organized by batch on trays and may be labeled with the pertinentdata including lot number, product identification, cook date,pasteurization data, etc. and placed in a freezer unit until shipping isrequired in step 1017. Much of the data may be transferred from the racklabel information. The process may end for that batch of product in step1018.

It is noted herein that appropriate quality control measures, such asinspecting packages for seal defects, before and after pasteurizationmay be performed as may be required. In one implementation thepasteurized packages are cooled down to approximately 41 degrees F.within a certain period of time such as 5 hours. Exact time might varyaccording to load. In one implementation the pasteurized simulated baconproduct may be flash frozen if same day shipping is required. Postpasteurization package cooling information is also documented in step1017. Any packages with loose packaging/air are to be set aside in lugs,labeled for REPACK with Lot code, date, what the product identification,and placed in a refrigerator unit for repackaging.

FIG. 11 is a process flow chart 1100 depicting steps for quality controlscanning bacon strip packages and final packaging of multiple singlepackages for later shipment. Packaged bacon stored after pasteurizationmay be retrieved from cold storage in step 1101. The retrieved packagesmay be cleaned and dried off at step 1102 in preparation for finalpackaging.

In step 1103 sleeves are applied to each package. Sleeves are gluedtogether using minimal glue and are pre-printed with “Best by Date”sticker. Stickers may also include the lot code, refrigeration data, andfreeze data relative to product creation data. Sleeved packages may besent through an X-Ray process (machine) to check packages for foreignobjects. In one implementation the packages are again checked for finalweight during the X-Ray process.

It is determined in step 1105 whether the packages pass or fail theX-Ray examination and weight check if applicable. If a package fails theprocess as determined in step 1105, the packages is rejected at step1106. If a package passes the process as determined in step 1105, thepassing batch of packaged product is placed in a shipping carton. Thecartons are labeled with all of the pertinent information in step 1108.In step 1109 each carton or case of packaged product may be overwrappedwith plastic and then placed in a freezer unit in step 1110 ready toship. In one implementation, product-filled cases are placed on aconveyor with the front of the case facing left. Cases are conveyedacross a Master Case Date Coder which prints the UPC code, Lot code,refrigeration date, frozen date and identification of product. Each casereceives overwrap, is palletized and placed in cooler.

It will be apparent to one with skill in the art that the simulatedbacon manufacturing process and product of the invention may be providedusing some or all of the mentioned features and ingredients, and theprocessing may be done in different ways without departing from thespirit and scope of the present invention. It will also be apparent tothe skilled artisan that the embodiments described above are specificexamples of a single broader invention that may have greater scope thanany of the singular descriptions taught. There may be many alterationsmade in the descriptions without departing from the spirit and scope ofthe present invention.

It will also be apparent to the skilled person that the arrangement ofelements and functionality for the invention is described in differentembodiments in which each is exemplary of an implementation of theinvention. These exemplary descriptions do not preclude otherimplementations and use cases not described in detail. The elements andfunctions may vary, as there are a variety of ways the hardware may beimplemented and in which the processes may be provided within the scopeof the invention. The invention is limited only by the breadth of theclaims below.

The invention is claimed as follows:
 1. A product comprising: simulatedbacon slices consisting of, as ingredients, (i) a mixture of Adzukibeans, liquid smoke and water, (ii) a mixture of buckwheat groats, waterand liquid smoke, (iii) wheat gluten flour, and (iv) one or moreadditional ingredients selected from the group consisting of onionpowder, bacon flavor powder, nutritional yeast, smoked paprika, soysauce, salt, tomato paste, coconut oil, maple syrup, apple cidervinegar, evaporated cane juice, annatto, tomato powder, and hickorysmoke; and a topping sauce comprising mixed bacon seasoning, coconut oiland liquid smoke; the adzuki beans are blended throughout the simulatedbacon slices, and the simulated bacon slices with the topping sauce arepackaged and labeled as a simulated bacon product.
 2. The product ofclaim 1, wherein the Adzuki beans and the buckwheat groats togethercomprise at least sixty percent by weight of the ingredients.
 3. Theproduct of claim 1, wherein the one or more additional ingredients inthe simulated bacon slices comprise nutritional yeast.
 4. The product ofclaim 1, wherein the topping sauce further comprises olive oil.
 5. Theproduct of claim 1, wherein the simulated bacon slices are made by aprocess comprising blending (i) the mixture of Adzuki beans, liquidsmoke and water, (ii) the mixture of buckwheat groats, water and liquidsmoke, and (iii) the wheat gluten flour together in a mixer to form ablended bacon base.
 6. The product of claim 5, wherein the one or moreadditional ingredients in the simulated bacon slices comprise coconutoil, and the blended bacon base comprises the coconut oil.
 7. Theproduct of claim 1, wherein the topping sauce is made by a processcomprising combining the mixed bacon seasoning, coconut oil and liquidsmoke using at least one of a whisk, an emersion blender or a mixer.